Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
  • H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
  • H01R13/405—Securing in non-demountable manner, e.g. moulding, riveting
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
  • H01R4/02—Soldered or welded connections
  • H01R4/023—Soldered or welded connections between cables or wires and terminals
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
  • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
  • H01R43/0228—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections without preliminary removing of insulation before soldering or welding
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
  • H01R13/46—Bases; Cases
  • H01R13/53—Bases or cases for heavy duty; Bases or cases for high voltage with means for preventing corona or arcing
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
  • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
  • H01R43/0263—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections for positioning or holding parts during soldering or welding process
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R9/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
  • H01R9/22—Bases, e.g. strip, block, panel
  • H01R9/24—Terminal blocks
  • H01R9/2416—Means for guiding or retaining wires or cables connected to terminal blocks

Definitions

• the insulated wires are stripped of the insulating material a small distance from the end of the wires, and a contact is crimped, soldered, or welded to the end of the wire. These contacts are then inserted into a connector body forming the array aforementioned.
• a wire management comb is presented wherein insulated electrical wire is attached to an electrical contact array such that very high voltage can exist between adjacent wires without voltage breakdown or leakage. The ability of these
• connections to sustain a voltage between adjacent contacts depends largely upon the distance between them, the shortest path along any joining surface being the important consideration. In the electronics field, these distances can be very small such that voltages of as little as 100VDC can cause deleterious leakage. A configuration that will allow voltage of 5000VDC between adjacent wires and these contacts would be desirable.
• the tails of a contact array are positioned in slots of an insulated management comb.
• the slots are deep enough to provide distance from one tail to its nearest neighbor along the surface of the insulation greater than the direct distance between them.
• weld locations are provided in staggered array such that the distance along the surface of the management combs from one weld site to its nearest neighbor is larger than the distance between contacts.
• the tails of the contacts stop short of the end of the management combs such that the distance allowing the surface of the combs from one contact end to its nearest neighbor is larger than the distance between contacts.
• the wires are welded without removing the insulation by utilizing a heated electrode that melts through the insulation to contact the electrical conductor. This site and the end of the insulated wire constitute the only exposed conductor. These sites are isolated by the configuration of the management comb.
• an electrical connector includes: an array of contacts; and a header that holds the contacts in position relative to one another; wherein the connector may include one or more of the following: the header is made of plastic; the header is molded around the contacts; the header includes a comb that supports contact tails of the contacts; the contact tails are in slots of the comb; the slots have open spaces adjacent to a back face of the header, that the contact tails do not extend into; the slots have widened portions that allow insertion of an electrode for electrically welding conductors to the contact tails; the widened portions are staggered, at different distances from the back face of the header; the widened portions alternate being relatively close to the back face, and relatively far from the back face; the comb has bottom holes at locations corresponding to the locations of the widened portions; the bottom holes are configured to allow insertion of an electrode for welding; and the bottom holes allow access to undersides of the contact tails.
• a method of securing wires to contact tails of contacts includes: placing the wires in slots in a dielectric material comb, wherein the contact tails are in the slots; and electrically welding conductors of the wires to the contact tails, within the slots; wherein the method may include one or more of the following: inserting a first welding electrode into widened portions of the slots; the widened portions are located at different distances relative to a back face of the comb; the first electrode is a heated electrode; insulation of the wires in the vicinity of the widened portions, is thereby melted with the heated electrode, exposing portions of the conductors of the wires; inserting a second electrode into bottom holes of the comb that correspond in location to the widened portions; the second electrode is an unheated electrode; the unheated electrode contacts a metal surface of a contact tail to be welded; and the welding includes welding the exposed portions of the conductors to the contact tails using the electrodes.
• an electrical connector includes: an array of contacts; and a header that holds the contacts in position relative to one another.
• the header includes a comb that supports contact tails of the contacts. The contact tails are in slots of the comb.
• a method of securing wires to contact tails of contacts includes: placing the wires in slots in a dielectric material comb, wherein the contact tails are in the slots; and welding conductors of the wires to the contact tails, within the slots.
• Fig. 1 is an oblique view of an electrical connector part in accordance with an embodiment of the invention.
• Fig. 2 is a cross-sectional view of part of the electrical connector part of Fig. 1 .
• Fig. 3 is a plan view of the electrical connector part of Fig. 1 .
• FIG. 3 is another plan view of the electrical connector part of Fig. 1 .
• Fig. 5 is an oblique, partially fragmented view of the electrical connector part of Fig. 1 , with wire coupled to contact tails of the electrical connector part.
• a linear connector contact array is presented with focus on the tails of the contacts that are connected to individual wires.
• a wire management comb made from dielectric material positions each wire over its contact's tail. The wire is attached to the tail by electrically welding the wire to the tail without removing the insulating material. This is accomplished with a heated welding electrode that melts through the insulator material until electrical contact is made with the wire. A non- heated electrode is beneath the tail to complete this circuit.
• the wire management comb has deep channels into which each wire resides. These channels form insulating ribs between adjacent wires such that the path along the surface of the management comb from one wire to its closest neighbor is very much larger than the distances between wires.
• weld sites are staggered such that the distance between weld sites is larger than the distance between wires.
• exposed ends of the contact tails are held short of the end of the management comb such that the path along the surface of the comb from the end of one contact to its nearest neighbor is much longer than the distance between adjacent wires.
• Fig. 1 shows a connector part 10 that includes a dielectric material header 12 that is used for holding an array of contacts 14.
• the connector that includes the connector part 10 may have other parts, such as a housing (not shown).
• the contacts 14 are used to make electrical connection with corresponding contacts (not shown) in a mating connector (not shown).
• the contacts 14 are made of a suitable electrically conductive material, for example copper.
• the contacts 14 in the illustrated embodiment are hermaphroditic contacts, but the contacts 14 alternatively may have any of a variety of other configurations.
• the header 12 is a single molded plastic piece that includes a comb 20 that is used for managing electrical connections between wires (not shown in Fig. 1 ) and tails 24 of the contacts 14.
• the header 12 may also include other parts, such as posts 26 surrounding parts of individual of the contacts 14.
• the comb 20 has a series of slots 28 in its top surface 30 that allow wires to be placed therein to make contact with the tails 24.
• the slots 28 are deep enough to provide enhanced electrical isolation between adjacent of the contact tails 24. This is illustrated in Fig. 2, which shows a back view of the connector part 10.
• An electrical isolation path 32 between adjacent of the contact tails 24, around the dielectric material of the comb 20, is much longer than a direct spacing 34 between the contact tails 24.
• the intervening dielectric material of the comb 20 greatly increases the electrical isolation of the contact tails 24 from one another. This helps prevent current leakage or voltage breakdown between the contact tails 24.
• the slots 28 have respective widened portions 40 which are weld locators, used for indicating the locations where inserted wires are to be welded to the contact tails 24.
• the widened portions 40 are staggered, having different distances from a back face 44 of the comb 20.
• the widened portions 40 are at two distances from the back face 44, alternating between ones relatively close to the back face 44, and ones relatively far from the back face 44.
• the comb 20 also includes bottom holes 50 that allow access from the bottom of the header 12, at locations corresponding to those of the slot widened portions 40, for welding wires to the contact tails 24.
• the bottom holes 50 allow access to undersides of the contact tails 24.
• the staggered locations for the widened portions 40 aid in electrically isolating the contact tails 24 from one another.
• An electrical isolation path 52 from the widened portions 40 of adjacent of the contact tails 24 is longer than the direct spacing 34 between the contact tails 24. Due to the staggering of the widened portions 40, the omission of dielectric material for the widened portions 40 does not result in a shorter electrical path between adjacent of the widened portions 40.
• the path 52 may be about the same length as the path 32 (Fig. 2).
• Fig. 4 shows how the tails 24 stop well short of the back face 44 of the comb 20, leaving open spaces 60 at the ends of the slots 28, with no conductive material in them.
• This arrangement makes for an electrical isolation path 62 around the back face 44, between adjacent of the contact tails 24, that is longer than the direct spacing 34 between the contact tails 24.
• the path 62 may be about the same length as the path 32 (Fig. 2) and/or the path 52 (Fig. 3). Alternatively the paths 32, 52, and 62 may all have different lengths.
• Fig. 5 shows wires 64 welded to the contact tails 24.
• the wires 64 may be welded to the contact tails 24 without removing the insulation 66 by utilizing a heated electrode (not shown) that is inserted down the widened portions 40.
• the heated electrode melts through the insulation 66 to contact the electrical conductor 68 that runs through the center of the wire 64.
• This site and the end of the insulated wire 64 constitute the only exposed parts of conductor 68. These sites are isolated by the configuration of the management comb 20.
• An additional electrode (not shown) is inserted through the bottom hole 50.
• the additional electrode is an unheated electrode that cooperates with the heated electrode to weld the electrical conductor 68 to the contact tail 24.
• the configuration of the comb 20 provides good electrical isolation between the contact tails 24.
• the isolation paths 32, 52, and 62 are all significantly longer than the direct spacing 34 between the contact tails 24. These long isolation paths reduce the risk of current leakage and voltage breakdown.
• the comb of the header may include any suitable number of contacts.
• other configurations may be used in coupling wires to contacts.

Landscapes

• Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Manufacturing Of Electrical Connectors (AREA)
• Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
• Coupling Device And Connection With Printed Circuit (AREA)
• Multi-Conductor Connections (AREA)

Priority Applications (2)

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Publications (2)

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Country Status (3)

Cited By (1)

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• 2012
  • 2012-05-03 EP EP12779625.8A patent/EP2705574B1/de active Active
  • 2012-05-03 WO PCT/US2012/036267 patent/WO2012151368A2/en active Application Filing
  • 2012-05-03 US US14/115,593 patent/US9225096B2/en active Active

Non-Patent Citations (2)

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